PLM User`s Manual
Contents
1. The PLM Setup Software allows a PLM unit to be configured from a PC for a particular target application new PLM unit must be configured before its initial use in order to specify sensor type display units etc This section covers the basic configuration of the PLM Advanced functions are also covered in the PLM Communications and Sensor Calibration sections Computer requirements The PLM setup software runs under Windows 95 98 ME NT4 2000 or XP operating systems The minimum recommended PC specification is a Pentium 90 with 16MB RAM and a serial port Connecting to a PLM The PLM connects to the PC with a standard straight through serial communication cable from the PC serial port to the 9pin Female PLM connector During PC operations sending or retrieving the PLM should be powered using the sensor loom Installing PLM Setup The PLM Setup software can be installed either from the MoTeC Resource CD supplied with the PLM or from the MoTeC website software motec com au To start the program after installation click on Start gt Programs gt MoTeC gt PLM Setup gt PLM Setup Configurations The PLM configuration determines exactly how a unit will operates The PLM Setup software allows changes to be made to a configuration to change PLM characteristics such as the sensor type display units analog output scaling backlight intensity etc MoTeC PLM Setup Software 13 Standard configuration templates for m2. CAN Collect functionality is the preferred method for communications from more than one PLM to an ADL For basic CAN communications with an M800 ECU the Address parameter for Message 1 should be 460 for the first PLM 461 for second PLM etc Only advanced users should change the other CAN message settings or configure Collect Master functionality CAN Messages are covered in more detail in the PLM Communications section 18 PLM Setup Software Setup Analog Output Output Table The Output Table Setup dialog is displayed when the Output Tables button is clicked Note that the two tables setup in this dialog are the same tables used for displayed values transmitted values and analog outputs but each function can use either table 1 or table 2 Output Function This parameter specifies input to the analog output Calibration Table The Ip and lpn options are the raw and normalized sensor pump cell currents Ipn is normalized using the calibration method specified under Setup Sensor The other options are the two tables that are specified under the Output Tables setup Calibration Table The calibration table allows users to set the voltage output that corresponds to the table input value The table takes the input value and translates it to an analog voltage 0 to 5 volts by way of the calibration table The voltage is linearly interpolated between points in the table so at least two pairs of values must be ent
3. La 0 500 Aout 0 000V La 1 750 Aout 5 000V ECU Configuration Lambda Sensor Calibration 39 MoTeC Meter or MoTeC AFM1 Meter Digital inputs Digital Input 1 can be enabled as a switch input or RPM input If the input is enabled the PLM can be configured to operate based on the switch state active high or active low or on a non zero RPM reading The RPM reading is also transmitted in the CAN and RS232 data streams Digital Input 2 can be enabled as a switch input and the PLM can be configured to operate based on the switch state active high or active low This input can also be configured to change the display units on the PLM display For more information see Setup Digital Inputs in the PLM Setup Software section The digital inputs have a 4 7kohm pull up resistor and a switching threshold of around 2 5volts 6 Meter Operation Communications RS232 Interface The RS232 interface is used for configuring the PLM from a PC and for transmitting data to third party equipment For configuration from a PC the PLM can be directly connected using a standard straight through 9 pin serial cable See Appendix PC Comms Wiring for details on wiring to a PC CAN Interface The CAN interface is used for transmitting data to MoTeC devices such as the ADL Advanced Dash Logger or M800 ECU or to third party equipment that supports CAN The CAN communications can be configured to allow one PLM unit to collec
4. can transmit up to four CAN messages containing readings and diagnostics The format of these four messages is fixed see Appendix M CAN Messages Format but the following parameters can be configured by the user for each message under the Setup CAN Messages menu Address Format Standard address formatting is recommended for most applications Extended addressing should normally only be used if required for interfacing to third party equipment however it is supported by the ADL if required Address The CAN address for a message is specified in hex The recommended address range for PLM messages is hex 460 to hex 46F Compound ID The compound ID 0 to 255 is placed in the first data byte of the CAN message and is used to differentiate between messages sent to a single CAN address Multiple messages can be transmitted to a single address by specifying different compound IDs for each message Message Rate The message rate 1 2 5 10 20 or 50 times per second determines how often the CAN message is transmitted Scaling The scaling of the actual reading for the PLM is determined by the Output to Transmit parameter which specifies the output table to be used for transmitted values eg Lambda O2 concentration etc MoTeC PLM Communications 23 For use with MoTeC equipment ADL or M800 the selected table must be setup for Lambda with 3 decimal places Other table setups should only be used for interfacing with thir
5. the PLM firmware version 0021 The calibration stored in the PLM is corrupt CRC failure MoTeC Appendices 33 Appendix C PLM CAN Diagnostic Codes These are the bit field descriptions for the diagnostic error groups that are sent to the ADL via the CAN link Diagnostic Group 1 1 No Sensor 2 Sensor Hot 4 Sensor Cold 8 Sensor Faulty 32 Warm Up 64 Ref voltage out of range Diagnostic Group 2 These codes correspond to those displayed by the PLM 1 C 1 Checking Operation 2 C 2 Control Initialization 4 C 3 Warm Up 8 C 4 No heater detected 16 C 5 User Stop sensor turned off via digital input 32 C 6 Sensor Protection Shutdown 34 Appendices Appendix D PLM Connector Details Sensor Connector Male D9 a ip 6 Battery OV Power is 9 22 Auxiliary Connector Female D9 6 CANLo Noe3 8 Analog out Note 4 9 Analog out Note 4 Note1 Extension of Standard Sensor Loom The length of the standard loom supplied for connection of the PLM to a sensor is 2 5m Longer looms are available from MoTeC by request It is not recommended that the loom is extended by using a standard serial cable These are unable to supply the current required by the sensor If an extension is made the wire thickness must be at least 20 gauge Note 2 Power Supply Current If using a power supply other than the vehicle battery start up current for the senso
6. to 25 seconds Backlight Intensity Backlight intensity is configurable from 0 to 100 Setup Digital Inputs Device Activation If digital inputs are not used for PLM activation the Run always option should be selected The remaining four options allow the PLM to be activated either while a digital input 1 or 2 remains active or after a digital input 1 or 2 first becomes active If one of digital input device activation modes is selected the corresponding digital input mode must be configured as Active Low Active High or Measure RPM This allows the PLM to be configured to operate only when measuring RPM or when a switch is set Input 1 Mode Off digital input 1 is disabled Active High digital input 1 is active when the input voltage is high Active Low digital input 1 is active when the input voltage is low Measure RPM digital input 1 is active when a non zero RPM is measured and the RPM value is transmitted in the CAN and RS232 data streams if configured under the communications setup RPM Pulses per Revolution If Input 1 Mode is Measure RPM the number of pulses per engine revolution must be specified here to calibrate the RPM measurement MoTeC PLM Setup Software 17 Input 2 Mode Off digital input 2 is disabled Active High digital input 2 is active when the input voltage is high Active Low digital input 2 is active when the input voltage is lo
7. xxx xC Byte X ohm Diagnostic Field 1 Sensor RUN Sensor COLD Sensor FAULT Sensor WARM UP ADC Ref fault 7 Sensor state RUN CONTROL_WAIT PUMP_WAIT WARM_UP NO_HEATER STOP PUMP_OFF O O1 P D WO PD PD MoTeC Appendices 49 Message 2 RES Jee 3 Sense voltage Byte 5 X mV Vp Pump cell voltage Byte 10000 255 5000 X mV 5 Reserved Ip Raw pump cell current Hi Lo 1 X uA Message 3 Byte Name Scaling Compound ID user defined N A SS 2_ a Eu 6 Battery Voltage Byte 1 xxV 7 Sensor in control Sensor voltage within limits Sensor voltage outside limits 50 Appendices Message 4 ES Compound ID user defined N A default 3 voltage voltage 3 Sensor type NONE NTK BOSCH LSU4 BOSHC LSU4 2 4 Reset source Note 2 Low Voltage reset Illegal Address reset Illegal operation reset Watchdog timer reset External reset 2 3 PLM 1 Master PLM Calibrated Sensor Output Value Note 1 Note 1 Note 1 Reserved Reserved Note 1 Note 1 Note 1 Compound ID 5 MoTeC Appendices 51 Message 7 0 COMpoundiD 6 NA PLM 7 Calibrated Sensor Output Value Hi Lo 1 x xxxLa Note 1 Note 1 Note 1 Message 8 0 Compound ID 7 Note 1 Note 1 Note 1 Message 9 0 Compound ID 8 Note 1 Note 1 Note 1 Message 10 0 Compud D 9 1 Reserved IN
8. A Eg PLM 16 Calibrated Sensor Output Value Hi Lo 1 x xxxLa e 1 47 Reserved 52 Appendices Note 1 Calibrated Sensor Output Value is x xxxLa when the PLM is setup to transmit Lambda with 3 decimal places as recommended for connection to MoTeC equipment Note 2 Low Voltage reset this is the only reset code that should be seen in normal operation External reset this reset code may be seen after upgrading firmware MoTeC Appendices 53 Appendix N RS232 Message Format Master PLM Message o Header 0 0x80 mo PLM 1 Master Calibrated sensor reading 8 9 PLM3Calibrated sensor reading Hiito xxxxta ie 32 33 PLM 15 Calibrated sensor reading 34 35 PLM 16 Calibrated sensor reading 36 37 Checksum Hi Lo 16 bit sum of unsigned bytes 0 to 35 Non Master PLM Message o Header O 0x80 0 0 3 __ Datalengh 8 6 Sensor cold status Sensor faulty status AAA 86 Sensor control state 5 en Beneer in contol stays o ooo Sensor in control status n 1011 Hilo RPM 12 13 Checksum 16 bit sum of SE bytes 0 to 54 Appendices Appendix O Recommended CAN Collect Configuration The following configuration is recommended for connecting multiple PLM units to an ADL Master Unit PLM 1 CAN Message 2 Message Rate OFF CAN Messages Message Rate OFF CAN Message 4 Message Rate OFF CAN Message 1 Address Format Compound
9. ID Master Message Rate Address PLM 2 Hex 461 PLM 3 Hex 462 PLM 4 Hex 463 PLM 5 Hex 464 PLM 6 Hex 465 PLM 7 Hex 466 PLM 8 Hex 467 PLM 9 Hex 468 PLM 10 Hex 469 MoTeC Appendices 55 PLM 11 Hex 46A PLM 12 Hex 46B PLM 13 Hex 46C PLM 14 Hex 46D PLM 15 Hex 46E PLM 16 Hex 46F Message Rate CAN Message 2 Message Rate ADL Use the CAN template PLM Collect 16 Channel and enable ie tick the channels required By default the template has the first 8 channels enabled This template places PLM values in the following channels ADL Channel Lambda Cyl 1 PLM 1 Master PLM Reading Lambda Cyl 2 Lambda Cyl 3 Lambda Cyl 4 Lambda 5 Lambda Cyi 6 Lambda Cy 7 Lambda Gy 8 Lambda Cy 9 56 Appendices Lambda Cyl 10 PLM 10 Reading Lambda Cyl 11 PLM 11 Reading Lambda Cyl 12 PLM 12 Reading MoTeC Appendix P Dimensions Appendices 57 58 Notes MoTeC Notes 59
10. MoTeC PLM User s Manual Contents uta da 3 Meter Op ration nn cantines 4 Connections ss E 4 Connectors sis aaa ata a dat ada Meo toga ett HL Ma co aa i i Rad a a 4 Analog se kab ee A DO nets 4 Digital A puts 5 Communications er Erunt EUER ERR the RA 6 PLM Display nr AA uet re 6 Sensor Placement 7 Sensor Warm up Sensor Lifetime Lambda Engine Tuning Reese PLM Setup Software se 12 Computer requirements 12 Connecting to a PLM Installing PLM Setup Gonfigurations 2 ata ALLA at api sii a ga n Managing Configurations 13 Changing Configurations essem 14 Sensor Calibration eee 19 Introduction REPRE 19 Calibration Meth Od 4 203 cocina aan een 19 Use Measured Calibration Value eeens 19 Enter Calibration Value 19 Calculate from O2 Concentration Free Air 20 Enter Calibration Table 21 PLM Communications 22 CAN MeSSages ua teria t re ra ac a E i Pat aa 22 Configuring Basic CAN with an 23 Configuring basic CAN with an 800 23 CAN Gollect F nctionalily ccce rect
11. N Bus is less than 2m 7ft long then a single termination resistor may be used The resistor should be placed at the opposite end of the CAN Bus to the CAN Cable connector MoTeC Appendices 43 Appendix PC Comms Wiring A PC may be connected to the PLM by connecting to the 9 pin female connector as shown below This allows the PLM to be configured using the PLM Configuration software It is also acceptable to use a standard 1 1 male to female communications cable which connects all 9 pins Note that during configuration the PLM must also have power connected to it via the PLM 9 pin male connector PC Serial Port Standard Serial Comms cable This will connect all 9 pins but only 3 wires are required 44 Appendices Appendix J Analog Output Wiring Floating Measuring Device When connected to a floating measuring device such as a multimeter Aout should be connected to Battery as shown to ensure that the full output voltage swing is available See the specifications for details Floating PLM Measuring Device A out A out Battery Battery Single Ended Input Measuring Device A single ended measuring device has the negative input internally connected to the devices ground pin Note The Ground voltage must not be more than 4 5 volts below Battery Note If the Ground voltage is greater than the Battery voltage then the PLM output voltage swing will be reduced See the specifications
12. O sensor Differential User Programmable 10mA Short circuit protected 0 to 4 5V relative to the negative output when the negative output is less than OV and greater than negative 4 5V relative to Battery and for output currents less than 1mA If the negative output is greater than OV then the output voltage swing will be reduced by the voltage on the negative output relative to Battery If the negative output is connected to a floating device such as a multimeter or other high impedance measuring device then it will float in the range 1 25V to 2 5V this will reduce the output voltage swing by 2 5V to 0 to 2V In this case connecting the negative output to Battery will restore the full output voltage swing Must be within 4 5 to 5 volts relative to Battery The negative out put has an impedance of approximately 5kohm connected to a variable voltage in the range 1 25V to 2 5V relative to Battery 4 5V relative to Battery for current less than 1mA 30 Specifications Max Positive Pin Output Voltage Inputs Digital Communications CAN RS232 Display Type Digit Height Lighting Connection Connectors Environment Temperature Range Case Dimensions WxHxD Weight 4 5V relative to Battery for current less than 1mA 2 x User Programmable as RPM or PLM Operate 1Mbit 9600 baud 8 data bits no parity 1 stop bit 9600 8N1 LCD 3 5 Digit 12 7mm Green LED Back Light 2 x 9 Pin D
13. RS232 Messages Note that the number of decimal places for calibrated sensor readings depends on the selected output table in the PLM configuration The transmitted messages conform to the MoTeC generic data protocol and are sent at 9600 baud 8 data bit no parity 1 stop bit 9600 8N1 28 Specifications Specifications Meter Power Supply Input Voltage Range Input current Protection Load Dump Clamp Sensors Sensors Compatible Types Calibration Methods Type Detection Sensor Thread Max Exhaust Temp Normal Temp Range Measurements Lambda 02 A F Ratio Accuracy 7 to 16Volts 60mA typical backlight off 110mA typical backlight on Plus sensor heater current Reverse polarity protected Max 40V at 100 Amp 100msec 1 Bosch LSU 4 Bosch LSU 4 2 NTK UEGO Automatic using sensor s built in calibration resistor Manual Table Entry Known Oxygen Environment Calibration Constant Manual M18 x 1 5 850 deg 150 800 deg 0 7 to 32 0 0 to 2296 Fuel dependant see lambda range 1 596 sensor specific MoTeC Sensor Heater Outputs Current Control Output Output Type Calibration Max Output Current Output Voltage Swing Negative Pin Output Voltage Range Min Positive Pin Output Voltage Specifications 29 1 Max 8 Amp Bosch Digital PID NTK Constant Voltage Voltage supply to the PLM should be at least 11V for proper operation of the sensor heater when using an NTK UEG
14. a data ma 24 Configuring the CAN collect master unit PLM 1 24 Configuring the CAN Collect slave units PLM 2 to PLM MoTeC PLM User s Manual CAN Unit Number Display iii 26 RS232 Messages mms a d a e 27 Specificatlons mts 28 clc 28 Appendices pi w adi 31 Appendix A Lambda to Air Fuel Ratio Table 31 Appendix B PLM Display Codes pi Appendix C PLM CAN Diagnostic Codes nene nenea 33 Appendix D PLM Connector Details 34 Appendix E Sensor Wiring Details 36 Bosch LSU 4 Sensor 36 NTK UEGO Sensor 38 Appendix F PLM to ECU Wiring Details 40 ET e Bel CANI TTT Appendix G PLM to ADL Wiring Details Appendix General CAN Bus Wiring Appendix PC Comms Wiring Appendix J Analog Output Wiring Lei ane Appendix Digital Input Wiring Typical wiring for Typical wiring for RPM measurement Appendix E Glossary iii nana leale retener ia Appendix M CAN Messages Format Appendix N RS232 Message Format Appendix O Recommended CAN Collect Configuration Appendix P Dimensions 2 2 20 ca Copyright Motec Pty Ltd 2001 2005 The information in this document is subject to change without notice While every effort is taken to ensure correctness no responsibility will be taken fo
15. d party equipment Configuring Basic CAN with an ADL To connect a small number of PLM units maximum of six to an ADL the ADL must use one CAN template PLM 1 to PLM 6 for each PLM The PLM units must be configured as follows to match the ADL templates Output To Transmit LA V1 with 3 decimal places in the table Address Format As per ADL template 460 to 465 Compound ld Message 1 0 Message 2 1 Message 3 2 Message 4 3 Message Rate Message 1 User defined Message 2 User defined Message 3 User defined Message 4 User defined Collect Master Off Configuring basic CAN with an M800 Up to 12 PLM units can transmit to an M800 ECU if configured as follows Output To Transmit LA V1 with 3 decimal places in the table Address Format Standard Address PLM 1 460 PLM 2 461 PLM 12 46F 24 PLM Communications Compound ld Message 1 0 Message Rate Message 1 User defined Message 2 Off Message 3 Off Message 4 Off Collect Master Off CAN Collect Functionality For applications involving multiple PLM units a single PLM can be configured to collect calibrated lambda readings from up to 15 other PLMs on the CAN bus and to retransmit the 16 readings on a single CAN address This functionality is available in PLM firmware V1 1 and later Note that only the calibrated lambda reading is collected and re transmitted If the CAN collect feature is used PLM Diagnostic CAN messages may still b
16. e turned on but care must be taken in assigning addresses not to interfere with messages from the other PLMs Configuring the CAN collect master unit PLM 1 Only one PLM on the CAN bus should be configured as a Collect Master To enable the CAN collect functionality a base address and a message rate must be specified in the Collect Master tab of the CAN Message Setup dialog CAN Message Setup Bit Rate Output To Transmit LA V1 Y Output Tables Message 1 Message 2 Message 3 Message 4 Collect Master Base Address 460 Message Rate MoTeC PLM Communications 25 The base address is the address on which the collected Lambda values will be retransmitted This address must lie on a 16 message boundary i e the address in hex must end in 0 The base address also defined the addresses of the Collect slave units that the master will monitor The recommended address is Hex 460 The message rate is the rate at which the Lambda values are retransmitted on the CAN bus to the measuring device usually an ADL or ECU Messages 1 to 4 do not need to be configured on the master unit Output to Transmit must be LA V1 with 3 decimal places in the table setup The master PLM unit will briefly display CU 1 Collect Unit 1 on start up after displaying the firmware version If the slave PLM stops transmitting to the master PLM for 1 5 seconds then the master PLM will retransmit a value of 0 for the missing
17. ered in the table Once created calibration tables can be saved using the Save As button and reloaded using the Load button for use in other configurations Default Output The analog output voltage is set to the Default Output voltage if the PLM is not active or if the analog output is disabled MoTeC Sensor Calibration 19 Sensor Calibration Introduction The NTK and Bosch lambda sensors are factory calibrated with a trimming resistor embedded in the sensor connector This resistor value can be read by the PLM and used to calibrate the sensor readings for a new sensor As sensors age their calibration changes To maintain accurate readings the PLM allows comparison of the measured 02 concentration in air against that of the pure O2 reference in the sensor itself to calculate a new calibration Sensor calibration values in the PLM Setup software are expressed as either an equivalent calibration resistor value or as a gain factor It is recommended that all applications that require sensor calibration values to be measured and recorded such as workshops using multiple sensors should use the gain factor calibration number rather than the equivalent resistor Support for equivalent resistor calibration values is included for backwards compatibility with previous PLM software Calibration Methods There are four calibration methods available under the Setup Sensor menu Use Measured Calibration Value The facto
18. for details Single Ended Measuring Device A out A out Battery Battery Ground Differential Input Measuring Device When connected to a differential input measuring device Aout should be connected to Battery as shown to ensure that the full output voltage swing is available See the specifications for details MoTeC Appendices 45 Note Aout and Aout must be within the within the input common mode range of the measuring device This limits the voltage difference that can be between Battery and Ground Differential Input PLM Measurina Device A out Input A out Input Batterv Ground Battery Ground 46 Appendices Appendix K Digital Input Wiring Typical wiring for switches PLM Digital Input 1 2 OV Typical wiring for RPM measurement PLM RPM Sensor Must be Hall Effect type Digital Input 1 8V sensor 9 p Signal supply OV Sensor OV MoTeC Appendices Appendix L Glossary CAN Controller Area Network High speed serial data bus common in automotive applications lp Sensor pump cell current Ipn Normalised Ip Vs Sense voltage 47 48 Appendices Appendix M CAN Messages Format Messages 1 to 4 can be optionally transmitted from any PLM unit Messages 5 to 10 are only transmitted from a PLM unit configured as a CAN Collect Master Message 1 Compound ID user defined default 0 user defined default Lambda Byte 195 10 500
19. for one second after the firmware version has been displayed The unit number is useful for trouble shooting systems containing multiple PLMs The unit number displayed is based on whether the unit is a Collect Master and on the least significant digit of the CAN address specified for CAN Message 1 as shown below Display PLM Number UO PLM 0 Collect Master disabled Message 1 disabled Message Rate Off MoTeC PLM Communications 27 PLM 1 Collect Master enabled U1 PLM 1 Collect Master disabled Message 1 address xx0 U2 PLM 2 Collect Master disabled Message 1 address xx1 U16 PLM 16 Collect Master disabled Message 1 address xxF A correctly configured network of PLMs using the CAN collect functionality should have the unit numbers CU1 U2 U3 U4 etc A correctly configured network of PLMs that are not using the CAN collect functionality should have the unit numbers U1 U2 U3 U4 etc A correctly configured PLM that is not using CAN communication should have the unit number UO RS232 Messages The PLM transmits RS232 status messages at a rate of 20 times a second If the PLM is configured as a CAN Collect Master then the transmitted message contains the Lambda values for the master PLM and up to 15 slave PLMs If the PLM is not configured as a CAN Collect Master the transmitted message contains Lambda values and diagnostics for the PLM Appendix N RS232 Message Format describes the format of the
20. guration has been created or modified it should be saved with a meaningful name by selecting File Save or File Save As from the main menu Sending a configuration to a PLM To send a configuration to a PLM select Online Send Configuration from the main menu To specify the serial port used for the connection to the PLM 14 PLM Setup Software select Options Communications Port from the main menu The PC must be connected to the powered PLM using the serial port specified When a configuration file is sent to the PLM any changes are automatically saved to the current configuration file on the PC Changing Configurations Once an existing configuration file has been opened or retrieved or a new configuration has been created the configuration may be modified by choosing the options under the Setup menu Setup Sensor Sensor The sensor type used with the PLM NTK Bosch LSU 4 or Bosch LSU 4 2 must be specified before a configuration can be sent to a PLM It is important to select the correct sensor type to prevent damage to the sensor and ensure correct lambda measurements Calibration There are several options available for choosing the calibration method of the sensor being used The default option Use measured calibration value allows the PLM to determine the factory sensor calibration and can be used in most cases If the calibration value of the sensor is known then it can be entered by selecting the op
21. he more accurate the calibration will be To start the calibration process click the Calibrate button The following dialog is displayed while the sensor readings stabilize 02 Concentration Calibration waiting for PLM reading to stabilise Ip reading 4 981 m filtered 5 028 m difference 0 9 mes When the sensor reading is stable the calibration can be stored by clicking the Store button as shown below 02 Concentration Calibration PLM Reading stable Press Store to save the reading Ip reading 5 067 m filtered 5 073 m difference 0 1 2 Store The new calibration value is displayed as both a gain factor and an equivalent resistor calibration This calibration can be recorded against the sensor serial number to allow the sensor to be used with another PLM unit by simply entering the calibration value MoTeC Sensor Calibration 21 To apply the new calibration the PLM configuration must be saved and sent to the PLM Enter Calibration Table For advanced applications a calibration table can be specified to calculate Ipn normalized sensor pump cell current from Ip sensor pump cell current At least two pairs of values must be specified in the table and linear interpolation is used between the points Calibration tables may be saved and reloaded for use in other calibrations 22 PLM Communications PLM Communications CAN Messages The PLM
22. ill maintain the accuracy of the sensor over its lifetime Sensor Temperature It is important to ensure that the sensor is not overheated due to incorrect placement in the exhaust as this significantly reduces the sensor life The sensor impedance Zp is measured by the PLM and this is a reasonable indication of sensor temperature Zp should be approximately 80 Ohms in normal operation If Zp is less than 60 the sensor is being overheated by the exhaust and the sensor life will be reduced Lambda Lambda gives a measure of Air Fuel Ratio that is independent of the type of fuel being used Lambda 1 0 corresponas to the stoichiometric ratio i e when there is no excess fuel and no excess air Lambda gt 1 0 gt Excess Air Lean Lambda lt 1 0 gt Excess Fuel Rich Lambda may be directly converted to Air Fuel Ratio for a specific fuel using a multiplication factor The PLM will display Air Fuel Ratio by loading the appropriate configuration into one of the output tables For more information see Setup Display in the PLM Setup Software section A table to convert Lambda to Air Fuel Ratio for various fuels is given in Appendix A Lambda to Air Fuel Ratio Table Engine Tuning The desired Air Fuel Ratio or Lambda is dependant on the tuning objective i e Power Economy or Emissions Normally at full load the engine is tuned for MoTeC Meter Operation 11 maximum power and at light loads the engine is tuned for em
23. issions or economy The following table gives a guide to the required Lambda values for different tuning objectives Power 0 84 to 0 90 Note The exact requirements for a specific engine and fuel must be found by experimentation Note On Turbo Engines extra fuel may be desirable to reduce exhaust temperatures and help avoid knock Note If the vehicle is fitted with a catalytic converter extra fuel may be required to ensure the catalyst does not overheat when not operating at Lambda 1 00 Operating Tips If the Engine misfires for any reason including an over rich mixture the Meter may falsely read Lean This is due to excess air being present in the exhaust gasses which is caused by incomplete combustion when the engine misfires Other areas that can give misleading readings include at high RPM closed throttle when the mixture won t burn completely Following overrun fuel cut the sensor will become saturated with oxygen and can take up to several seconds to resume accurate readings Engine misfires include hitting the rev limiter be it a fuel or ignition cut or a combination of both and can give a similar result with time being required to purge the sensor of excess oxygen or fuel Engines with high overlap camshafts running at low speed may pump air through the engine resulting in a false lean reading therefore the meter may need to read leaner than would otherwise be expected 12 PLM Setup Software PLM Setup Software
24. nable to supply the current required by the sensor heater If an extension is made the wire must be at least 20 gauge Female Connector The female PLM connector has pins for serial connection to a PC CAN data bus 2 digital inputs and the analog voltage output The pinout is assigned to allow direct connection to a PC with a standard straight through 9 pin serial cable Note that the PC must have a serial communications port normally marked COM1 A custom cable is required to use the other features on this connector Analog Output The analog output provides a voltage proportional to Lambda The scaling of the analog output can be changed by using the PLM Setup software to configure the device see Setup Analog Output in the PLM Setup Software section MoTeC Meter Operation 5 The analog output is provided as a differential voltage using two connector pins Analog Out and Analog Out For correct operation Analog Out must be connected to the ground reference on the monitoring system The analog output can be configured as a wide band sensor input into a MoTeC ECU for tuning as described below See Appendix F PLM to ECU Wiring Details for wiring details M4 M48 ECU PLM Configuration Output Function LA V1 table La 0 000 Aout 0 000V La 5 000 Aout 5 000V ECU Configuration Lambda Sensor Calibration 1 Narrow Band or MoTeC AF Meter M8 M800 PLM Configuration Output Function LA V1 table
25. ores two tables that can be configured with different calibrations for displaying lambda air fuel ratio or equivalence ratio In addition to a lambda calibration there are a number of pre defined calibrations for air fuel ratio for different fuels To display one of these the calibration must be loaded by clicking on the Load button and choosing the appropriate calibration from the list displayed Advanced users can generate their own calibration tables using the Ipn normalised sensor pump cell current value measured by the meter These user calibrations can be saved for re use by clicking the Save As button Output to Display The default PLM display value can be selected as the result from one of the two tables that are specified under the Output Tables setup Display Decimals Table 1 Table 2 This is the number of decimals used to display the values from Table 1 and Table 2 in the Output Tables setup The display decimals are specified for both tables as the PLM can be configured to swap the display between the two tables using a digital input Normal use would be to 2 decimal places for lambda 16 PLM Setup Software Display Update Rate The update rate of the displayed value can be from 1 to 10 times per second Filter Time The display data can be filtered so that it is more stable and easier to read This filtering is independent of the update rate The filter time can be specified in 0 1second units from 0
26. ost common preferences are included with the software Managing Configurations When the PLM Setup software is started a configuration file needs to loaded before changes can be made or before a configuration can be sent to the PLM This configuration can either be loaded from a file on disk retrieved from the PLM using the serial cable or created as a new configuration A loaded configuration can be saved to a file on disk and then sent to the PLM using the serial cable A modified configuration must be sent to the PLM for it to take effect Creating a new configuration To create a new configuration select File Newfrom the main menu and choose a template to base the new configuration on Loading an existing configuration from disk To open an existing configuration file select File Open from the main menu and select the desired file The most recently used files may be opened from the list of files at the bottom of the File menu Retrieving an existing configuration from a PLM To retrieve a configuration from a PLM select Online Get Configuration from the main menu To specify the serial port used for the connection to the PLM select Options Communications Port from the main menu The PC must be connected to the powered PLM using the serial port specified It is advisable to retrieve the initial configuration from the PLM and save this before making modifications Saving a configuration to disk After a confi
27. perature The Bosch LSU will take 20seconds to heat up while the NTK 30 seconds before reading The maximum continuous operating temperature of the sensors is 850 degrees and sensors should not be used for a prolonged period at temperatures higher than this The sensor can be heated to 930 degrees for a short period not exceeding 10 minutes but the accuracy may be reduced Sensor Lifetime The sensor life time is dependant on the type of fuel being used and the volume of gas flow over the sensor The sensor can also be contaminated by exhaust manifold sealants so Exhaust Gas Sensor friendly sealants should be used Leaded fuel will reduce the sensor lifetime substantially due to lead contamination of the sensor element Typically for high performance engines the sensor should last at least 500 Hrs in unleaded fuel and 50 Hrs in leaded fuel Longer lifetimes can be expected for less demanding applications 10 Meter Operation At the end of its life the sensor becomes slow to respond and does not read rich properly The NTK and LSU are designed to be accurate for 50 000km of operation in a road car so the above figures are a conservative estimate Sensor lifetime will be reduced by contaminants such as lead silicon oil etc Thermal cycling will also age the sensor more rapidly along with exposure to exhaust fumes without any heating control active ie not connected to the PLM Regular performance of the Free Air Calibration w
28. r is up to 5A though operating current is much lower than this 0 5 1 Amps depending on exhaust gas temperature MoTeC Appendices 35 Note 3 Wiring See Appendix G PLM to ADL Wiring Details for CAN wiring to an ADL See Appendix F PLM to ECU Wiring Details for CAN wiring to an M800 ECU See Appendix H General CAN Bus Wiring for recommended CAN wiring practices Note 4 Analog Output Connect the Analog out to the input on the measuring device Connect the Analog out to the OV reference point on the measuring device Analog out must be connected for the measuring device to make a correct reading See Appendix F PLM to ECU Wiring Details for wiring the analog outputs to M4 M48 M8 amp M800 ECUs 36 Appendices Appendix E Sensor Wiring Details Bosch LSU 4 Sensor KX R av 0 los ee AES 0 i I Hoster Heater Sensor Common Ys Ipr Wiring Details MoTeC Bosch LSU 4 2 Sensor Wiring Details Appendices 37 38 Appendices NTK UEGO Sensor Wile 7 Red 6 Sensor Common Sensor Common RC 5 TL 6312 W1 Heater 4 Heater uote Appendices Wiring Details NTK UEGO 1 zi 40 Appendices Appendix F PLM to ECU Wiring Details Analog Output PLM wiring using the Analog Output to M4 M48 M8 M800 ECUSs PLM M4 M48 CAN One or more PLMs may be connected to the M800 ECU via the CAN bus Note
29. r the consequences of any inaccuracies or omissions in this manual 23 June 2005 MoTeC PLM Setup Software 3 Introduction The MoTeC Professional Lambda Meter measures Lambda or Air Fuel Ratio over a wide range of mixtures with fast response time The display may be set to Show Lambda Air Fuel Ratio for Petrol Alcohol Gas Diesel or blend fuel equivalence ratio or percentage oxygen The PLM provides a differential Analog Output Voltage proportional to Lambda that may be connected to an Analog Meter or other measurement instrument such as an ECU Data Logger or dynamometer The PLM also supports RS232 and CAN data links to devices such as the Motec Dash Logger or M800 ECU for transmission of sensor and diagnostic data This manual covers the configuration and operation of the meter 4 Meter Operation Meter Operation PLM Connections Connectors The PLM has a male and a female D 9 pin connector See Appendix D PLM Connector Details for a description of the PLM pinout Male Connector The loom supplied with the PLM is fitted to the male PLM connector for connection to the sensor and to a power supply The Power supply must provide enough current up to 5 Amps at start up for both the meter and the sensor heater element The vehicle battery is typically the most convenient source of power It is not recommended that the power and sensor loom be extended by using a standard serial cable These are u
30. ry calibration resistor is measured by the PLM and used to calibrating readings The factory sensor plug must be present to use this calibration method Enter Calibration Value A previously measured calibration value can be entered directly as either an equivalent calibration resistor value or as a gain factor value Entered calibration values are useful when sensors are calibrated using the free air calibration 02 concentration The results of the free air calibration can be recorded for a particular sensor and then entered when the sensor is used with another PLM 20 Sensor Calibration Calculate from O2 Concentration Free Air This calibration method uses the known oxygen concentration of free air to calibrate a sensor Re calibration using this method allows a sensor to maintain accuracy as it ages To perform the free air calibration the PLM must be powered up and connected to a PC with a serial cable running the PLM Setup software The configuration in the PLM must match the sensor type being used for the calibration Free air calibration must be done in the open air not in a workshop or dyno room where there will be large amounts of hydrocarbons in the atmosphere The O2 Concentration parameter specifies the actual concentration of Oxygen in the atmosphere and should be entered if known A nominal value of 20 94 is given but the more accurately this is known for current atmospheric conditions temperature pressure t
31. sensor tip protruding into the exhaust gas flow The sensor placement should be on an angle of between 10 and 90 degrees to the vertical with the tip of the sensor pointing down This is to ensure that no condensed water builds up between the sensor case and the sensor ceramic It should not be placed vertically due to excess heat soak in this position It is recommended that where possible the sensor be placed at least 1m from the exhaust ports to avoid excessive heat and at least 1m from the open end of the exhaust system to avoid incorrect readings due to outside oxygen This is however not mandatory and where necessary for shorter exhaust systems the sensor should be placed closer to the engine The placement of the sensor should be away from the flame front coming out of the cylinder head and away from areas where one cylinder may have more affect than another 8 Meter Operation ne Correct sensor placement x Incorrect sensor placement MoTeC Meter Operation 9 Exhaust slip joints should be avoided near sensor placement as some designs allow air to enter Slip joints can be reversed to make them better for use near sensors Introduced air No air introduced LLLA c Exhaust flow ee N Exhaust slip joint design to avoid incorrect lambda readings Sensor Warm up The internal heater in the LSU or NTK sensor is powerful enough to allow accurate measurement when gas temperature is at room tem
32. slave Configuring the CAN Collect slave units PLM 2 to PLM 16 The Message 1 tab of the CAN Message Setup dialog must be configured as follows Output To Transmit LA V1 with 3 decimal places in the table Address Format Compound Message Rate As required for application This is the rate at which the Lambda value for this unit will be sent to the master unit Address Master PLM Collect Master Base Address PLM number 1 in hexadecimal Eg For a master PLM base address Hex 460 PLM 5 address would be Hex 464 PLM 12 address would be Hex 46B 26 PLM Communications CAN Message Setup Bit Rate Output To Transmit L V1 Y Output Tables Message 1 Message 2 Message 3 Message 4 Collect Master Address Format Standard Extended Address 461 Compound ID 00 Message Rate 20 per second w Messages 2 to 4 are not required and should be OFF on the slave units The Collect Master message rate must be set to OFF on the slave units A PLM configured as a slave unit will briefly display the PLM unit number eg U 4 for PLM 4 on start up after displaying the firmware version Appendix O Recommended CAN Collect Configuration describes the recommended configuration for connecting multiple PLM units to an ADL CAN Unit Number Display On power up a PLM will display a unit number based on the current CAN communications configuration This unit number is displayed
33. sub commonly called D9 10 to 70 Deg C 105x41x25 mm Excluding Connector 135grams MoTeC Appendices 31 Appendices Appendix A Lambda to Air Fuel Ratio Table Air Fuel Ratio 32 Appendices Appendix B PLM Display Codes Warm up Codes C 6 Sensor Protection Shutdown The C 6 state is entered when the PLM can not pump enough current into the pump cell to balance the sense cell When C 6 is entered pump current is turned off The PLM will try to gain control of the sensor the C 1 state every 10 seconds If it is then unable to regain control after 2 seconds then it will re enter the C 6 state C 5 User Stop The sensor has been turned off via a digital input 4 No Heater detected This will occur if the sensor is disconnected or the heater is open circuit ie the sensor is damaged Heater circuit should be approx 3ohms at room temp C 3 Warm Up The PLM is heating the sensor prior to normal operation and waiting for sensor to warm up C 2 Control Initialization Waiting to start pump current C 1 Checking Operation Waiting to get control of sensor cell voltage In normal operation the PLM will display C 3 C 2 C 1 then start reading lambda values The C 4 and C 6 error states will occur if a problem is detected Error Codes 0010 The config loaded into the PLM does not match the PLM firmware version 0011 The config stored in the PLM is corrupt CRC failure 0020 The factory calibration values does not match
34. t CAN data from up to 15 other PLM units and then retransmit the data on a single CAN address and on the RS232 interface For detailed information on communications interfaces see the PLM Communications section PLM Display Start up Display On powerup the PLM displays the current firmware version eg 1 1 0 for one second followed by a unit number based on the current CAN communications configuration This unit number displayed for one second is useful for troubleshooting networks of multiple PLM units See the PLM Communications section for more detail on displayed unit numbers Status Display Whenever the sensor is not in control or is warming up a series of displayed codes describes the current status A description of these codes is given in Appendix B PLM Display Codes MoTeC Meter Operation 7 If the PLM loses control of the sensor at any point then the sensor warm up process is repeated and these codes are displayed again Sensor Readings The displayed format of sensor readings can be configured to select the display units decimal places update rates and filtering For more information see Setup Display in the PLM Setup Software section If the reading is too large to be displayed using the configured settings the display will only show Backlighting The backlight intensity is configurable from 0 to 100 Sensor Placement The sensor should be fitted to the exhaust system with the
35. that the ECU version must be V3 0 or higher See Appendix H General CAN Bus Wiring for details on correct wiring and termination for CAN devices MoTeC Appendices 41 Appendix G PLM to ADL Wiring Details One or more PLMs may be connected to the MoTeC ADL via the CAN bus See Appendix H General CAN Bus Wiring for details on correct wiring and termination for CAN devices 42 Appendices Appendix H General CAN Bus Wiring The CAN bus should consist of a twisted pair trunk with 100R 0 25Watt terminating resistors at each end of the trunk The preferred cable for the trunk is 100R Data Cable but twisted 224 Tefzel is usually OK The maximum length of the bus is 16m 50ft including the MoTeC CAN Cable PC to CAN Bus Communications Cable CAN Devices such as MoTeC PLM ADL etc may be connected to the trunk with up to 500mm 20in of twisted wire The connector for the CAN Communications Cable may also be connected to the trunk with up to 500mm 20in of twisted wire and should be within 500mm of one end of the trunk If desired two CAN Cable connectors may be used so that the MoTeC CAN Cable may be connected to either side of the vehicle Both connectors must be within 500mm of each end of the trunk CAN Cable Connector 100R Terminating R sistors at sach These wires must be Twisted end ofthe CAN Bus Minimum one twist per 50mm 2in zz 500mm CAN Bus Short CAN Bus If the CA
36. tion Enter calibration value This value is engraved on sensors supplied by MoTeC as an equivalent resistor calibration value Either of these two options will be sufficient in nearly all situations The more advanced calibration methods Calculate from O2 concentration and Enter calibration table are described in the section Sensor Calibration Heater Control This parameter allows the heater voltage to be set when using an NTK sensor For most situations this can be left at the default value of 10 5 volts A value of 12 12 5 volts will give better results during cold start or warm up calibrations or during extensive periods of overrun fuel cut where the sensor may become too cold for accurate measurement Running the MoTeC PLM Setup Software 15 heater at a sustained voltage above 10 5 volts will reduce the sensor lifetime Sensor Timeout The option to ignore sensor errors is only recommended for very specialised applications where extreme changes in lambda may cause a short loss of sensor control Enabling this option will disable the default PLM behaviour of shutting down the sensor for a timeout period when control is lost This timeout is to protect the sensor as loss of control can indicate a wiring fault Setup Display Output Tables The Output Table Setup dialog is displayed when the Output Tables button is clicked The Output Tables are used by the PLM to calculate the displayed value The PLM st
37. w Display Other Output Table When Low the other output table is used for the display value while digital input 2 is low For example if Output to Display in the Setup Display menu is table 2 then table 1 will be displayed while digital input 2 is low Setup CAN Messages The configuration templates included with PLM Setup are all configured to send CAN data to a MoTeC ADL Advanced Dash Logger or M800 ECU by default The Output to Transmit parameter specifies the output table to be used for transmitted values The Output Table Setup dialog is displayed when the Output Tables button is clicked Note that the two tables setup in this dialog are used for displayed values transmitted values and analog outputs but each function can use either table 1 or table 2 For use with MoTeC equipment ADL or M800 the selected table must be setup for Lambda with 3 decimal places Other table setups should only be used for interfacing with third party equipment For basic CAN communications with an ADL the Address parameter for Message 1 should match the address in the PLM CAN communications template loaded in the ADL If multiple PLMs up to six units are connected to an ADL then each should be given a different address The addresses chosen must match those of the PLM CAN communication templates provided with Dash Manager For example the ADL template PLM 1 CAN ID 460 requires that the Message 1 Address be 460 Note that
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